1.Drive a screwdriver into the center of the sealing cap. 2.Bend the screwdriver back to remove the sealing cap.
<>TRANSAXLE CASE REMOVAL 1.Remove all sixteen bolts securing the transaxle case to the clutch housing.
2.Use snap ring pliers to expand the indicated snap ring. The snap ring will separate from the ball bearing groove, and the output shaft assembly will fall under its own weight.
CAUTION: Do not use a scraper or chisel to remove the transaxle case.
3.Remove the transaxle case from the clutch housing.
<>SPRING PIN REMOVAL
1.Shift the 5th-reverse shift fork in the direction shown in the illustration. 2.Using a pin punch, remove the spring pin from the shift fork and rail.
1.Shift the 3rd-4th speed shift fork and 5th speed-reverse shift fork in the direction shown.
2.Pull up on the 3rd-4th speed shift rail and 5th speed-reverse shift rail and take them out of the hole in the clutch housing. 3.Slide the 3rd-4th speed shift rail and 5th speed-reverse shift rail in the direction shown and remove them together with the shift forks.
1.Pull out the shift rails from the shift rail holes in the clutch housing. 2.Remover the shift rails together with the shift forks.
<>INPUT SHAFT AND OUTPUT SHAFT REMOVAL
Remove the input and output shafts together.
<>DIFFERENTIAL/OUTPUT SHAFT/INPUT SHAFT REMOVAL
Remove the input and output shafts together.
ADJUSTMENT BEFORE ASSEMBLY SPACER SELECTION FOR DIFFERENTIAL CASE PRELOAD ADJUSTMENT
1.Put solders [1.6 mm (0.063 inch) diameter, about 10 mm (0.39 inch) long] in the illustrated positions of the transaxle case. 2.Install the taper bearing outer race and differential assembly into the transaxle case.
NOTE: If necessary, replace the differential case and taper bearing before carrying out these adjustments.
3.Install the clutch housing and tighten the bolts to the specified torque. Tightening torque: 44 ± 5 Nm(33 ± 4 ft. lbs.)
4.Remove the clutch housing, and then remove the differential assembly. 5.Remove the outer race and take out crushed solders. 6.Measure the thickness of the crushed solder with a micrometer and select a spacer that will provide the standard preload value. Standard value: 0.05 - 0.11 mm (0.0020 - 0.0043 inch) preload
SPACER SELECTION FOR ADJUSTING INPUT SHAFT END PLAY/OUTPUT SHAFT PRELOAD/DIFFERENTIAL PRELOAD
1.Install the input shaft, output shaft and differential as a set to the clutch housing.
NOTE: If necessary, replace the input shaft, output shaft, differential case and/or bearings before carrying out these adjustments.
2.Put solders [1.6 mm (0.063 inch) diameter, about 10 mm (0.39 inch) long] on the input shaft rear bearing at the positions shown in the illustration.
3.Put solders [1.6 mm (0.063 inch) diameter, about 10 mm (0.39 inch) long] on the transaxle case at the positions shown in the illustration. 4.Install the bearing outer races of the differential and output shaft. 5.Install the transaxle case and tighten the bolts to the specified torque. Tightening torque: 44 ± 5 Nm(33 ± 4 ft. lbs.) 6.Remove the transaxle case. 7.Remove the outer races and take out the crushed solders.
8.Measure the thickness of the crushed solder with a micrometer and select spacers that will provide the standard end play/preload value. Standard value: Input shaft end play: 0.05 - 0.17 mm (0.0020 - 0.0067 inch) Output shaft preload: 0.13 - 0.18 mm (0.0051 - 0.0071 inch) Differential preload: 0.05 - 0.11 mm (0.0020 - 0.0043 inch)
